Method Statement For Fence Bridges and Drop Structures

SA FENCE AND GATE
Investment Holdings (Pty) Ltd
Eskom Enterprise
Kusile Power station
Doc No. SAFG Eskom Kusile

003/2012 Rev 0
Date: 2012/10/12
Pages: 36
METHOD STATEMENT
INSTALLATION OF FENCE BRIDGES AND DROP STRUCTURES
Documents Attached
1 Method Statement
2 QCP/ITP
3 Risk Assessment
Signature
Approved
by:
Project
Manager
SA Fence & Gate
Approved
by:
Project
Manager
Kusile Power Station
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Date
SA FENCE AND GATE

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INTRODUCTION
THE PURPOSE OF THIS DOCUMENT IS TO OUT LINE ALL THE WORK THAT SA
FENCE AND GATE WILL BE DOING DURING THE KUSILE PROJECT. THIS WILL
INCUDE ALL THE WORK PROCEDURES AND INSTRUCTION THAT ARE MADE BY
THE SHE AND KUSILE SPECIFICATIONS
SCOPE
THIS METHOD STATEMENT WILL APPLY TO THE INSTALATION OF BRIDGES AND
DROP STRUCTURES AS PER DRAWINGS SUPPLIED BY ESKOM KUSILE.
1.
2.
3.
4.
5.
6.
7.
8.
SITE ESTABLISHMENT
MATERIAL DELIVERY
DEFINITIONS,TERMS,ABBREVIATION
REFERENCES
RESPONSIBILITIES, AUTHORITY, ACCOUNTABILITY
STRIPPING AND STOCKPILLING AREAS
PLANT & TOOLS REQUIRED FOR THE ACTIVITY
EXCAVATION
8.1
Preparation for Excavations
8.1.1 Permission
8.1.2 Definitions (Excavations)
8.2
Layout of the area of construction
8.3
Excavation
8.4
Bedding
8.4.1
Levelling
8.4.2
Main Fill
8.4.3
Stockpiling of Surplus Material
9. CONCRETE WORKS
9.1
Definitions
9.2
Resources
9.3
Fixing of Reinforcing Steel
9.3.1
Cutting of Steel Reinforcement
9.3.2
Delivery and offloading of steel
9.3.3
Area of offloading
9.3.4
Fixing of Reinforcing Steel
9.4
Storage and transport on site of Reinforcing Steel
9.4.1
Area of storage
9.5
Placing and Fixing
9.5.1
Placing and Fixing
9.5.2 Corrective Action (if any)
9.6
Erection of Formwork
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SA FENCE AND GATE

9.6.1
9.6.2
9.6.3
9.6.4
9.6.5
9.6.6
9.6.7
9.6.8
10.
11.
12.
13.
Eskom Enterprise

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Delivery and offloading

Area of offloading
Outside Shuttering (Bottom slab Bridge)
Outside Shuttering (Drop Structures)
Centre Wall (Bridge)
Top Slab (Bridge)
Removal of Formwork
Corrective Action (if any)
9.7
Concrete Placement
9.7.1 Casting of Concrete - Ready Mix
9.7.2 Placing
9.7.2.1 Placing concrete in cold weather conditions
9.7.2.2 Placing concrete in hot weather conditions
9.7.3
Curing
9.7.3.1 Curing concrete in cold weather conditions
9.7.3.2 Curing concrete in hot weather conditions
9.7.4
Monitoring of Temperature
9.7.5
Testing
9.7.6
Concrete Repairs
9.7.6.1 Honey - Combing
9.7.6.2 Major Crack Repair
9.7.6.3 Map Cracking
9.7.6.4 Curling
9.7.6.5 Fine Dust forming on the surface
9.7.6.6 Pop-Outs
9.7.6.7 Flaking
CONTROLS AND CHECKS
CONSTRUCTION OF TEMPORARY DAMS
QUALITY CONTROL AND ASSURANCE
HEALTH AND SFETY
13.1
Terms, Definitions, Abbreviations
13.2
Responsibilities, Authority and Accounting SHEQ will ensure
13.3
SHE Implications/controls
13.3.1 Excavation
13.3.2 Bedding and Levelling
13.3.3 Backfilling
13.3.4 Delivery and Offloading of Steel
13.3.5 Placing and Fixing
13.3.6 Concrete works
13.3.7 Concrete Repairs
13.4
Using of a ladder
13.5
Personal Protective Equipment
13.6
First Aid, emergency equipment and procedure
13.7
Housekeeping (on daily basis)
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14. ENVIRONMENTAL
14.1
Vegetation Clearing and Topsoil Removal
14.2
Noise
14.3
Dust
14.4
Emergency preparedness
14.5
Accidental leaks and spillages
14.6
Flora and Fauna
14.7
Ablution facilities
14.8
Solid waste management
14.9
Accommodation of traffic
14.10
Landscaping and Rehabilitation
14.11
Prevention of fire
14.12
Installation
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1. SITE ESTABLISHMENT
Site Establishment was executed as per approved method statement.
2. MATERIAL DELIVERY
All material delivered to Kusile site will be delivered to SA Fence and
Gate site lay down area. All material will be inspected and approved by
client before installation as per quality control procedures (refer to Risk
Assessment RA 003) and transported to site by LDV with a trailer.
3. DEFINITIONS, TERMS, ABBREVIATIONS
QA/QC MEANS QUALITY ASSURANCE /QUALITY CONTROL OFFICER

PPE MEANS PERSONAL PROTECTIVE EQUIPMENT
EO MEANS ENVIROMENTAL OFFICER
CR MEANS CONSTRUCTION REGULATION
EMP MEANS ENVIROMENTAL MANAGEMENT PLAN
OHSA MEANS OCCUPATIONAL HEALTH AND SAFETY ACT
LDV MEANS LITE DELIVERY VEHICLE
MOD AASHTO MEANS Maximum density: The maximum density of a
material for a specific compaction effort is the highest density
obtainable when the compaction is carried out on the material at
varied moisture contents.
Optimum moisture content: The optimum moisture content for a
specific compaction effort is the moisture content at which the
maximum density is obtained.
4. REFERENCES
PROJECT KUSILE POWER STATION STANDARDS ENVIROMENTAL
SPECIFICATION
ENVIROMENTAL MANAGEMENT PLAN
CONSTRUCTION REGULATION 2003
OCCUPATIONAL HEALTH AND SAFETY ACT, ACT NO 85 OF 1993
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5. RESPONSIBILITIES, AUTHORITY, ACCOUNTABILITY

The preparation, review and approval of this procedure are the
responsibility of:
Preparation : Site Manager
Review : Contracts Manager
Approval : Project Manager (Eskom Kusile Power Station)
The requirements of this Method Statement is binding on all SA FENCE
AND GATE employees and contracting bodies.
Site Agent and Foreman are responsible for ensuring this activity is
carried out in accordance with this Method Statement.
QA/QC officers are also responsible for ensuring that this activity is
carried out in accordance with this Method Statement and that
necessary inspection will be done.
6. STRIPPING AND STOCKPILE AREA

Stripping shall be done for the following reasons:
Where construction vehicles will be moving
Where temporary facilities will be placed such as toilets
Where the bridges will be installed
The contractor shall strip the topsoil which includes the top 150mm of soil
(or to the depth of the bedrock where the soil is shallower than 150mm)
and root material of cleared vegetation, for subsequent use during
rehabilitation. Topsoil shall be stripped from all areas of the working area
where topsoil will be impacted by construction activities including areas for
temporary facilities, as directed by the Engineer.
Stockpile area shall be identified by Eskom power stations EO
(environmental officer) for SA Fence and Gate to comply to. Topsoil and
subsoil stockpiles shall not exceed 2m in height and shall be so placed as to
occupy the minimum width compatible with the natural angle of repose of
the material, and shall be taken to prevent the material from spreading
over too wide a surface.
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7. PLANT & TOOLS REQUIRED FOR THE ACTIVITY

Plant
Tipper truck
Bomag Roller 90
Excavator
TLB
Generator
Water Tank
Whacker
Water pumps
Drive unit + pokers
Compressor
Concrete spinner truck
Mobile crane
Banana Bucket
Poker vibrator
Tools:
Extension leads
Grinder
Skill saw
Hilti Drill (sps)
Breaker electrical
Picks
Shovels
Rakes
Shuttering
Scaffolding
Electric welder
Reinforcement
Dumpy Level
Theodolite
Hammers (14 Pound, 4 Pound and carpenter hammer)
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Spirit Level and builders line

Nails (75mm and 100mm)
Safety Harnesses
Wheel Barrow
8. EXCAVATION
8.1 Preparation for Excavations
8.1.1 Permission
Before any excavations starts, the contractor shall apply for permission
from the client (Eskom). Permission will be obtained by way of a permit to
excavate. It must be determined if any unknown services are present inside
the perimeter of the proposed excavation area. To do this the services of
expert detection equipment or personnel will be utilised and will be
included in the excavation permit.
8.1.2 Definitions (Excavations)
Excavation: The act of ground-breaking, digging and taking out of
earth; whether by hand or machine.
Bedding: The act of preparing earth with machines, to specified
standards, to ensure that the earth serves the desired purpose.
Backfilling: The act of reintroducing excavated material to a specific

area, either by hand or machine.
SANS: South African National Standards.

8.2. Layout of the area of construction
Once the permit for excavation has been obtained the layout of the bridges
and drop structures will be determined by the surveyor by incorporating
the information provided on the drawings (0.90/25041 rev0; 0.90/25042
rev 0; 0.90/23490 rev 0; 0.90/25019 rev 0; 0.90/23491 rev 0; 0.90/23492
rev 0 and K5406-027; K5406-034; K5406-051; K5406-053) in accordance
with the specific work needed. Profile stakes will be used in order to
control the depth of the excavation by use of bonding rods. The actual
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layout of the excavation area will be marked out by using either

lime/cement/small rocks as reference markers for the operator.
8.3 Excavation
All excavations shall be done by the following methods:
o Hand excavation
o TLB with small bucket
o K9 Digger
o Trencher
All excavations shall be carried out under supervision and the excavator
operator shall be trained, assessed and deemed competent to operate the
excavator, by the supervisor.
Excavated trenches shall be dug to a 45 degree angle.
The area of work will be cleared of topsoil for the width of the
excavations needed, to a minimum depth of 150mm or depth otherwise
specified by the Engineer. After the topsoil material has been removed it
will be stockpiled separately and reused after backfill.
A TLB, Tipper, Grader and a Compaction Roller will be utilised to reinstate the topsoil as per specifications received from the drawings.
Topsoil material will not be used as backfill.
Excavated material will be placed alongside the excavated base, at least
1.5m from the excavated area. There will be strictly adhered to the
dimensions or specifications for the width of the excavation to prevent
over excavation.
The depth of the excavation will periodically checked by a bonding rod
and profiles to control the depth.
Where hard material is encountered and which cannot be removed by
and excavator, an air breaker/jack hammers will be used to clear the hard
material.
Where possible, excavation will commence at the lowest point,
proceeding to the highest point. The Contractor (SA Fence and Gate) shall
prevent the ingress of water as far as possible by utilising pumping
equipment supplied to dewater the excavated area.
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All excavations are to be shored unless the excavation is sloped. Steep

shoring will be accomplished using timber shutter boards backed by
bracing planks. Written permission from the Contract Engineer will be
obtained before sloping.
The excavator shall be used according to its design and functionality.
Excavation required is for reinforcement, and post foundation as per
drawings (0.90/25041 rev0; 0.90/25042 rev 0; 0.90/23490 rev 0;
0.90/25019 rev 0; 0.90/23491 rev 0; 0.90/23492 rev 0 and K5406-027;
K5406-034; K5406-051; K5406-053)
The site plan from the client shall be used to avoid digging and damaging
underground services thereby endangering the safety and health of any
personnel. Testing to be done by Contractor prior to commencement of
worked to locate any underground services in planned work area.
The depth of the service must be known or determined to prevent
damages on services.
If any service is damaged Eskom will be notified immediately.
A pre-ignition start inspection shall be conducted prior to assume
excavation.
If flooding occurs, excavations shall be inspected by the Contractors
Engineer and a written report shall be submitted declaring the excavations
safe to work in.
8.4 Bedding
8.4.1 Levelling
Loose material will be removed from the excavated area. Bonding rods
and profiles will be used to level the work. Once the area is level, the
bottom will be compacted to 90% modified AASHTO maximum density or
as stipulated on the drawings. Boulders that exist within the area of
excavation will be removed and replaced with suitable material and
compacted. Only after Quality Control has signed off will bedding be laid.
Once level is correct, the bedding material will be compacted to 90%
modified AASHTO maximum density in layers of 150mm - 200mm or as
stipulated on the drawing.
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8.4.2 Main fill

Selected fill material will be used to backfill the excavated area in approved
layers until ground level. Heavier compaction equipment will be used to
compact the area. Density tests will be carried out on each layer to ensure
adherence to specifications. Water will also be utilised where necessary to
achieve the optimum moisture level required for optimal density.
8.4.3 Stockpiling of Surplus Material
Once all backfill operations have been completed all of the excess
excavated material (if any) will be loaded with appropriate plant and taken
to an approved soil stockpile site.
9. CONCRETE WORKS:
Placing of concrete; incorporating steel fixing, formwork erections,
placing/finishing of concrete; repairing of concrete.
9.1 Definitions:
Formwork: Temporary forms/boards used to support and shape
concrete to create a desired structure.
Cover: the distance between the outside face of the concrete and the
outside of the reinforcing steel within that element.
Slump: An indication of the cohesion and workability of a concrete mix.
9.2 Resources:
The following is a list of proposed plant and machinery that will be
utilised during the operation for the concrete works:
Concrete spinner truck
Mobile crane
Banana Bucket
Pocket vibrator
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ACTIVITIES:
9.3 Fixing of Reinforcing Steel
9.3.1 Cutting of Steel Reinforcement
Steels will be cut using a portable grinder or pliers used by somebody with
experience and who has been inducted.
All waste generated from grinding of reinforcement shall be disposed of at
demarcated areas as indicated by client.
All cutting equipment complied with OHS act in terms of safe guarding.
Safety goggles shall be used at all times to protect employees eyes from
sparks or hazardous material entering eyes.
9.3.2 Delivery and offloading of steel
All reinforcing steel will be delivered to the site offices and then delivered
to site with a LDV. Offloading will take place under supervision and the
required plant will be used to ensure safe and effective offloading. The
steel will be tagged for easy identification. Steel will be measured and
verified during offloading to comply with the quality standards of the
Contractor and the Client. The steel certificate will also be verified and kept
on record at time of delivery.
9.3.3 Area of offloading
To ensure safe and effective offloading the delivery vehicle will be situated
as close as possible to the offloading or storage area. Offloading will take
place in such a manner to ensure that the movement of plant and people
in site is not obstructed. Correct rigging practise will be implemented and
followed at all times.
Care will be taken not to damage the steel or the delivery vehicle while
offloading.
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9.3.4 Fixing of Reinforcing Steel

Steel reinforcement will be manually fixed as per drawing (0.90/25041
rev0; 0.90/25042 rev 0 and K5406-027; K5406-034; K5406-051; K5406053)
Labourers will use steel fixing pliers to fix reinforcements to each other
and to stools as per drawing (0.90/25041 rev0; 0.90/25042 rev 0 and
K5406-027; K5406-034; K5406-051; K5406-053)
9.4 Storage and transport on site of Reinforcing Steel
9.4.1 Area of storage
Steel will be stored at the site offices and transported to site or area of
fixing by a LDV. Steel will be stored in demarcated areas in labelled bundles
and care will be taken to prevent the steel from coming into contact with
soil or mud. When transported to site, the steel will be stored as close as
possible to the area of fixing as possible. All reinforcing steel will be
cleaned and free of debris before utilising it.
At the storage area the steel will be stacked no higher than 3 times the
smallest size of the base. Steel will be stacked in such a manner as to
ensure adequate space between stacks. Walkways will be kept clean and
clear.
Transport of steel to site will only take place with a vehicle that has gone
through the inspections and was issued with a permit. All operators will
have completed medical inspections and underwent induction before
transporting any material. The relevant permit for driving will also be
obtained. All operators will adhere to the Clients rule with regard to
driving; that is staying on designated roads and not drive into the veld. All
loads will be secured on the back of the vehicle or trailers.
9.5 Placing and Fixing
Using the applicable drawings as reference the reinforcing steel will be
placed and fixed into position, according to specific size and shapes, by
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means of tying the elements together with binding wire, suitable clips or by
welding where necessary. All reinforcing steel fixed in place will be cleaned
of mud, oil, loose rust or any other substances prior to concrete being
placed. Offcuts generated during fixing and installation of reinforcing steel
will be collected and removed for disposal prior to concrete being poured.
Where spacer/cover blocks are necessary, they will be cut to the required
size and shape and they will be off the required material. The blocks will be
secured to ensure that the necessary clearance, cover and spacing are
achieved.
Laps, joints and splices will be as indicated on the drawings or as directed
by the Engineer.
Protruding bars that will be exposed to the elements for prolonged periods
of time will be protected against corrosion with end caps in place.
9.5.2 Corrective Action (if any)
Any material utilised incorrectly will be removed and replaced correctly.
Any material that has been contaminated will be removed and disposed of
in the correct manner.
9.6 Erection of Formwork
9.6.1 Delivery and offloading
All formwork and false work will be delivered to site by the approved
supplier/contractor. Offloading will take under supervision and by utilising
the necessary resources.
9.6.2 Area of offloading
To ensure safe and effective offloading the delivery vehicle will be situated
as close as possible to the offloading or storage area. Offloading will take
place in such a manner to ensure that the movement of plant and people
in site is not obstructed. Correct rigging practise will be implemented and
followed at all times.
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Care will be taken not to damage the steel or the delivery vehicle while
offloading.
9.6.3 Outside Shuttering (Bottom slab - Bridges)
Start by setting out the outer layout of the bridge by chalking the outer
measurements (0.90/23490 rev 0; 0.90/25019 rev 0; 0.90/23491 rev 0;
0.90/23492 rev 0), then proceed to construct shuttering according to
layout.
Shuttering will be put in place, placed in line and stayed.
Shutter oil will be applied to shutters before the steel fixers commences
with work.
Steel fixers will then start with the bottom layer of steel which will be
placed on 50mm cover blocks.
Eskom will then inspect and after approval concrete will be placed by
concrete hands.
Concrete will be placed with shovels and concrete will be vibrated with a
drive unit with a 50mm poker.
Concrete will then be levelled and flouted.
After concrete has set, curing compound will be applied with a block
brush.
For full concrete specifications refer to clause 9.7 of this document.
9.6.4 Outside Shuttering (Drop Structures)
Start by setting out the outer layout of the drop structure by chalking
the outer measurements (Refer to drawings: K5406-027; K5406-034;
K5406-051; K5406-053), then proceed to construct shuttering according
to layout.
Shuttering will be put in place, placed in line and stayed.
Shutter oil will be applied with a block brush.
Steel fixers will then plait the steel horizontally and vertically.
Eskom will then inspect the work.
Concrete will then be poured with a crane or straight discharge.
Concrete will be vibrated with drive unit and 50 mm poker.
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Concrete will be levelled with shovels and straight edge.

Concrete will be flouted after it has set.
Curing compound will be applied with a block brush.
9.6.5 Centre Wall (Bridges)
Shuttering wall will be put in place, placed in line and stayed.

After inspection the second shutter wall will be put in place, placed in
line and stayed.
The last inspection will then take place (Cover Inspection).
Concrete will then be placed with crane and vibrated with drive unit and
50 mm poker.
After concrete has set all shutters will be manually stripped.
9.6.6 Top slab (Bridges)

Staging for the top slab will commence as soon as all shutters have been
stripped.
Shuttering wall will be put in place, placed in line and stayed.
After staging the decking panels will be installed for the top slab.
The outline of the top slab will be done as per drawing (0.90/23490 rev
0; 0.90/25019 rev 0; 0.90/23491 rev 0; 0.90/23492 rev 0).
Outside shutter will be constructed for top slab.
After steel reinforcements have been inspected the pouring of the
concrete will take place (refer to clause 9.7 of this document).
Concrete for top slab will stand for 7 days to cure, after which all
shuttering and staging will be stripped.
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Erection of the formwork will take place in accordance with the

specifications on the drawings using appropriate quantities of support
work to ensure the safety of these in the workings. Care will be taken to
ensure that all elements and materials used in the formwork are free of
defects to ensure that the formwork is stable and secure. The required
equipment such as clamps, jacks and fittings will be in good working
condition and of the correct design and strength.
The face of the formwork that comes in contact with the concrete will be of
the required specification to achieve the necessary concrete finish. The
panels that are joined together will be secured tightly to prevent leakage of
concrete. Temporary openings in the formwork will be left for inspection,
cleaning and placing of concrete.
The finished formwork will be inspected to check for alignment, evenness,
tightness of bolts, clamps ties and bracing. For the bottom and top slabs
the formwork will be erected and finalised before reinforcing steel is
installed. Where walls are erected the reinforcing steel will be fixed and
checked prior to the formwork being erected.
Openings and box outs will be provided only as shown on the drawings.
These will be rigid in construction and securely fixed in place to prevent
moving.
9.6.7 Removal of formwork
Only when the concrete is strong enough to support its own weight or any
loads applied to it, will the formwork be removed. The minimum time
formwork is to remain in place during normal conditions will be:
OPC
Rapid Hardening OPC
Walls
0.75
0.5
Slabs (propped)
Slab props
10
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Care will be taken to remove material carefully to prevent shock or damage

to the concrete surface. Any damage to the concrete caused by formwork
removal will be regarded as a defect in terms of SANS 1200 G clause 5.5.14
and repaired in accordance with the approved NCR and CAR repair
procedure which is found within SANS 1200 G. All formwork will be cleaned
and checked before reusing it.
Should the ambient temperature be considered cold, the period for
removal will be increased as specified in the SABS 1200 G - 1982 clause
5.2.5.2
9.6.8 Corrective Actions (if any)
Reparations of blemishes and defects on the surface will be done by using
mortar of the same cement sand ratio as the concrete being repaired.
Large defects will be repaired by approved methods only. If the integrity of
the concrete is in doubt, the whole structure will be rebuilt.
9.7 Concrete Placement
Ready mix concrete will be bought at Crocodile
9.7.1 Casting of Concrete - READY MIX
Before concrete is cast inspections will take place by a competent
person.
25Mpa ready mix will be delivered on site with a POD (Proof of Delivery)
that will be used by the employees.
The casting of the concrete will be done direct from the ready mix truck
by the use of the shoot; in case a wheelbarrow is needed it will be
available on site. It will be inspected on a daily basis.
For bottom slab concrete will be left overnight to cure.
A slump tests will be done and when cubes are being taken (the slump
must be 90mm). Cube samples (6 cubes) will be taken at least one per
day or per 50m3 of concrete.
Test cubes will be tested by an independent laboratory. 3 at 7 days and 3
at 28 days. Results will be forwarded to Eskom for verification.
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9.7.2 Placing
The necessary approval for concrete placing will be obtained prior to
placing and the element that needs to be cast will be inspected
beforehand. All unwanted debris and material such as water and loose soil
will be removed from the element before concrete placing. 2 Hours after
mixing the concrete, it will be placed in its final position.
A slump test will be conducted on the batch of cement when it arrives on
site. The measured slump will be within the following limits:
For reinforced walls and slabs - 70mm +- 25mm (or otherwise specified)
For reinforced floors - between 80mm +- 25mm (or otherwise specified)
The slump test will be carried out in accordance with SABS method 862 and
shall be determined from the approved average slump of the approved
trial mix as per Kusile specifications for structural concrete doc 203 770 Rev
04, clause VA.G.5.5.1.2.
In order to achieve the required slump, no additional water will be added
to the mix. In order to ensure that the concrete can be placed in the
corners of the formwork and around the reinforcing without segregation,
the consistency of the concrete will be of such standard to achieve this,
without segregation of the mix or the bleeding of water.
The concrete will be placed vertically, where possible, to prevent
segregation of the mix or the displacement of the reinforcing. The
concrete will not be allowed to free fall a height exceeding 1.5m unless
approved by the Engineer. The concrete will be brought in in layers of
450mm thickness and will not be worked by means of a vibrator to flow
laterally, so as to prevent segregation.
The angle of the shoot (if one is used) will be controlled to prevent
segregation. Baffles will be used to control the rate of discharge of the
cement when using a shoot. If a pump is used it will be approved by the
Engineer.
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A vibrating poker will be used to compact the concrete and the poker will
be inserted into the concrete to ensure vibration takes place from the
lower layer into upper layer. Attention will be given to ensure over
vibration does not take place. Concrete placing will take place in
accordance with compaction equipment available.
Finishing will take place by floating a wood or steel float depending on the
required surface finish. Construction joints will only be permitted where
indicated on the drawings. In the case of a plant breakdown, an emergency
construction joint will be finished in a way that least impairs the durability,
appearance and functioning of the concrete element.
In the event of heavy or prolonged rainfall, no concrete will be placed.
9.7.2.1 Placing concrete in cold weather conditions
Note: Cold weather is defined as a period when, for more than three
consecutive days, the average daily temperature is less than 4.44C [ACI
306.1-90]. When cold weather conditions are anticipated to be present the
concrete suppliers will be contacted to take the necessary precautions for
mixing the concrete.
No concrete will be placed on frozen sub grade due to bulking and freeze
thaw. Frozen sub grade material will be thawed thoroughly using external
heat and insulation prior to concreting. All concrete placements will be
vibrated mechanically.
9.7.2.2 Placing concrete in hot weather conditions
Note: Where the air temperature is above 30C, the temperature of the
placed concrete should not exceed 30C. Hot weather conditions are
therefore considered to be temperatures that exceed 30C. When hot
weather conditions are anticipated to be present the concrete suppliers
will be contacted to take the necessary precautions for mixing the
concrete.
To ensure that the concrete is placed at the right temperature the
following precautions will be taken:
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Shading the aggregates before placing

Spraying the aggregates with water to cause evaporative cooling
9.7.3 Curing
Curing of the concrete will take place, after the concrete has gained
sufficient strength and the formwork has been removed, by wetting the
surface continuously with a fine spray, covering the concrete with plastic
sheeting, or by applying an approved curing compound. Curing with take
place over a minimum period of 5 days and care will be taken not to
damage the surface of the concrete.
9.7.3.1 Curing concrete in cold weather conditions
Note: Cold weather is defined as a period when, for more than three
consecutive days, the average daily temperature is less than 4.44C [ACI
306.1-90]. When cold weather conditions are anticipated to be present the
concrete suppliers will be contacted to take the necessary precautions for
mixing the concrete.
In order to provide insulation against the cold conditions the concrete shall
remain in forms for as long as practicable possible. After the removal of the
forms, the structures will be covered by insulation blankets. Water curing
will also not take place in cold weather; instead curing compound will be
used to paint the face of the concrete. The curing will be applied for at
least 5 days.
9.7.3.2 Curing concrete in hot weather conditions
Note: Where the air temperature is above 30C, the temperature of the
placed concrete should not exceed 30C. Hot weather conditions are
therefore considered to be temperatures that exceed 30C.
When hot weather conditions are anticipated to be present the concrete
suppliers will be contacted to take the necessary precautions for mixing the
concrete.
Curing should receive special attention and should start as soon as possible
during hot weather.
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To ensure that the concrete cures correctly in hot weather the following
precautions will be taken:
Shade netting will be installed over the formwork to get the
temperature down.
After concrete has been floated, curing compound will be applied to
prevent cracks.
Programme concreting for the cooler parts of the day (early
morning, late afternoon).
Cooling formwork with water spray can also be considered.
9.7.4. Monitoring of Temperature
Thermostats will be used to determine the temperature and care will be
taken to ensure the temperature of the concrete, from the time of
hardening is maintained at not less than 5C for cold weather and not more
than 30C for hot weather.
9.7.5 Testing
The tolerances set out in the specifications by Eskom will be adhered to at
all time. These tolerances will apply to the fixing of reinforcing steel,
erecting the formwork and concreting of elements. Any deviations from
these tolerances will be approved by the Engineer.
In order to determine and ensure that the concrete is of the required
strength, cube moulds will be made of the placed concrete. Samples will be
taken as follows: 6 cube moulds will be made for each days cast element
and for at least every 50m placed. Only one sample will be taken of a
batch and only after 3 batches of the same strength concrete has been
mixed, will another sample be taken, unless otherwise instructed. The first
set of 3 cubes will be tested at 7 days curing and the second 3 cubes at 28
days. This is in accordance with Kusile Specifications for structural
concrete, clause VA.G.7.1.2. Sufficient slump cones and cube moulds will
be provided to ensure the correct frequency of sampling. The crushing of
the cubes will be conducted at an approved laboratory. All tests will be in
accordance with project specifications.
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9.7.6.1 Honey - Combing
In the event of Honey-Combing appearing the following will be
implemented to rectify the problem:
Ensure that all participating employees wear PPE. Remove any loose
material until structurally sound concrete is attained. Apply wet to dry
epoxy should the concrete be past green stage. Use shuttering to form up
the profile of the wall. Pour liquid non-stick grout to fill all voids. Cure for
72 hours. Strip shuttering. Do necessary quality checks. ABE-FC (grout) will
be used to fix honey combing and cracks between 0 and 10mm. ABE-FR
(grout) will be used for cracks larger than 10mm.
9.7.6.2 Major Crack Repair
In the event of major cracks appearing the following will be implemented
to rectify the problem:
Chip along the crack at least 2 cm in width and as deep as the crack
extends. The cavity will be cleared off all loose particles, dirt, grease, and
paint with a point tool or chisel. Moisten the substrate prior to application.
Apply the sealant as per manufacturers standard. Allow to dry and do
checks again.
9.7.6.3 Map Cracking
In the event of map cracks appearing the following will be implemented to
rectify the problem:
The large, central crack will be filled with latex caulk. The top of the caulk
gun will be inserted into the crack as far as possible. The crack will be filled
to the brim. A putty knife will be used to smooth the surface. A new, thin
coat of concrete shall be applied with a metal trowel. Allow several hours
for new concrete to set. The surface will be inspected and if necessary a
second layer of concrete will be applied. The concrete will then be covered
with a plastic tarp and left to cure for 7 days. Curing compound will be
sprayed on the surface daily to allow the concrete to cure evenly. After the
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curing process is complete two coats of sealant will be applied with a paint
roller.
9.7.6.4 Curling
In the event of Curling appearing the following will be implemented to
Grinding and grouting will be typically used on slabs. At the elevated edges
and corners and under slab voids holes will be drilled and filled with grout.
After the grout hardens, the curled edges shall be ground to the desired
profile. After the voids under the slab are grouted, the curled are will be
repaired by saw cutting around the area to be patched, chipping out
concrete below the desired profile, and patching to the required elevation.
9.7.6.5 Fine Dust forming on the surface
In the event of Fine Dust appearing the following will be implemented to
A chemical floor hardener will be applied. In severe cases the method of
grinding and polishing the surface can be utilised.
9.7.6.6 Pop - Outs
In the event of Pop-Outs appearing the following will be implemented to
Pop-outs will be repaired by first cleaning the holes out with a broom or
shop vacuum and a drill will be used to remove any unstable material. Each
hole will be filled with concrete using a trowel. Patching concrete with a
bonding agent will be used. Larger holes will be cleaned and a chisel will be
used to remove any loose material. Concrete will then be poured over the
area and spread with a trowel and left to cure.
9.7.6.7 Flaking
In the event of Flaking the following will be implemented to rectify the
problem:
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A pressure washer will be used to clean the surface of the concrete. Any
depressions caused by the flaking will be filled with epoxy mortar; all cracks
will be repaired using mortar. An acid wash will be applied which will
roughen up the floor surface so the primer will stick. The primer will be
applied and spread with a broom and concrete will be applied while the
floor is still wet. The concrete finish will be spread with a sponge while a
trowel will be used to detail the edges. A trowel or broom will be used to
create a finish texture. The finish will be allowed to cure for 24 hours.
10. CONTROLS AND CHECKS
The QC will continually perform spot checks on all working sites to ensure
adherence to all Method Statements/Process Controls. Refer to ITP. Should
a non-conformance be noted, a Non Conformance Report will be
completed and handed to the applicable person. A Non Conformance
Report register will be kept.
11. CONSTRUCTION OF TEMPORARY DAMS
Prior to commencement of bridges and drop structures temporarily
retaining dam walls will be constructed to ensure dry working space.
Gabions filled with dump rock (2m x 1m x 1m) will be used to form the
temporarily structure. Fill obtained from fence excavations will be
imported and compacted in layers at inner side of gabion wall 4m wide.
USB Green DPM will be inserted between gabions and filling to ensure a
water tight construction. To ensure the natural flow of water when
experience heavy rainfall, two 160mm diameter drains / overflows will be
inserted 800mm from the top of the temporarily structure. Water pumps
will also be used to ensure that rising water levels is not affecting
construction of permanent work. Permission and approval from the
Engineer will be obtained before constructing the temporary dam walls.
12. QUALITY CONTROL AND ASSURANCE
All quality control will be executed by SA Fence and Gate in conjunction
with prescribed specifications of Eskom.
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A Quality control officer of SA Fence and Gate will liaise with Eskoms
quality department to ensure that all requirements are met.
13. HEALTH AND SAFETY
This method statement will apply to the clearing, excavating, compacting
and loading of material, waste management, casting concrete, plant
equipment and PPE to be worn on site when carrying out this tasks/works
by SA FENCE AND GATE.
13.1 Terms, Definitions, Abbreviations
QA/QC Means Quality Assurance / Quality control Officer.
PPE Means Personal Protective Equipment.
SO Means Safety Officer
OHSA Means Occupational Health and Safety Act
EO Means Environmental Officer.
Excavation works Means the making of any man made cavity, trench,
pit or depression formed by cutting, digging, or scooping.
MSDS MEANS Material Safety Data Sheet.
13.2 Responsibilities, Authority and Accountability SHEQ will ensure :
Tool box talks will be carried out at the beginning of each work day with
all employees prior to work commencing.
No employee will be allowed access within the excavation area while the
TLB/Excavators are busy working.
Adherence to the 3m rule is compulsory at all times
Protection around the excavations will be installed. A barrier fence of at
least 1m high and as close to the excavations as possible will be
installed. Warning signs are to be posted on these barriers/fences.
All employees and contractors involved in this activity are competent to
do so.
All employees and contractors are required to conduct this work
undergo a SHEQ induction.
Employees must ensure that they were their PPE at all times.
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Dust masks are compulsory during dusty conditions.

Access ladders will be secured by tying them down at the top and
bottom.
All operators have to be licenced and certified. Copies of such
documents will be kept on file at the Site Office.
All employees and contractors involved in this activity are trained with
regards to the content of this Method Statement
13.3 SHE implications/controls
13.3.1 Excavation
Prior to work commencing at the start of each day, tool box talks will be
held with all employees.
No employee will be allowed access within the confines of the excavated
area whilst TLB/Excavators are busy excavating.
Spotters will be employed to ensure that no employee is dangerously
close to the TLB/Excavator.
All excavated trenches shall be barricaded to prevent any person/any
excavator and other construction vehicles on site from falling into the
trench or the excavation.
Employees must at all times ware PPE and dust mask are compulsory in
dusty conditions.
All operators must be licenced and certified.
13.3.2 Bedding and Levelling
No employees are allowed in areas where TLB/Excavators are busy
with removal of loose materials.
When compaction is taking place all employees are to be removed
from the area.
When a Whacker is being used to compact the soil the operator will
be changed every 30 minutes. The safe work procedure (SWP 001)
for the Whacker must be discussed with the employees and
signatures obtained.
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13.3.3 Backfilling
During backfilling the following will apply, and be adhered to at all times: The Foreman will be present at all times.
The Foreman is accountable for all employees at all times, and must
therefore be fully aware of the number and work-area of employees.
Spotter in place to direct trucks to the backfilling area.
Spotters to wear full PPE including long sleeve reflective vest, 500mm x
500mm red flag and whistle.
All employees to be cleared from areas where mobile machinery is at
work.
Employees to adhere to the 3m rule from moving machinery.
Trucks not to be overloaded.
Employees are not allowed to stand closer than 1 meter from the edge
of an excavation, to prevent any collapse of the sides of the excavation.
Excavation to remain fully barricaded until backfilling is level.
Backfilling materials will be obtained from approved areas only.
Operators must adhere to demarcated roads. No travelling in veld or
protected areas.
Before trucks discharge backfill material, stop blocks to be applied to
vehicle.
All valve chamber covers will be securely installed & clearly marked.
13.3.4 Delivery and Offloading of Steel
The driver of the delivery vehicle must have a valid drivers licence in
order for him to be allowed on site. All delivery vehicles will be escorted
to the offloading site by a licenced SA Fence and Gate employee. The
delivery truck must be compliant in the sense of not being overloaded
and the load must also be secured on the truck or vehicle.
The appointed stacking and storage foreman will be present to ensure
that stacking and storage is done correctly. Communication of the safe
work procedure for stacking and storage of material (SWP 002) should
be done with employees before work commences.
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All employees taking part in offloading of material must signs the

necessary documentation to indicate their compliance to the method of
offloading and the safe work procedure. The reinforcement steel will
only be offloaded in the designated offloading area approved by the
Engineer. The laydown area will be demarcated and barricaded with the
necessary signage and warnings attached and all employees must sign
the risk assessment form communicated to them regarding the laydown
area. No steel shall be stored outside the assigned area.
All employees involved in fixing steel, will have their gloves and safety
glasses on at all times. The supervisor will ensure compliance.
If there is a need to work at heights, access will be provided by means of
scaffolding. Scaffolding will be erected and inspected by trained and
competent employees. All scaffolding will have adequate bracing, toe
boards, knee rails and hand rails. All scaffolds will be on a register and
should be inspected after rain, heavy winds or any changes made to the
scaffolding.
All persons working at heights will have the required training and wear
double lanyard safety harnesses which will be hooked up at all times.
The fall protection plan will be discussed with all employees working on
heights. Tools being used on heights must have lanyards fitted to them
to prevent them from falling on employees at the bottom.
When bases being fixed get too large, and the employees have to walk
on the bases, scaffold boards are to be placed on top of the bases
creating a 600mm walkway, tied down to the reinforcing steel, for the
employees to walk on. No employees will be allowed on bare reinforced
steel.
When fixing soffits/suspended slabs, adequate hand railing and
barricading will be erected at +- 1m from the finished top of the
concrete level.
When fixing bases with vertical bars, care will be taken to temporarily fix
diagonal braces to counteract the potential for the bars to lean over and
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fall. Diagonal temporary stiffeners/braces will be installed at every 10m.

During long pours, no employee will exceed a 12 hour shifts.
13.3.6 Concrete works
Once the truck has arrived at the designated are a spotter will direct the
truck into position and ensure that no employees are in the vicinity of
the trucks. As soon as the truck is in place, stock blocks will be inserted
behind the wheels of the concrete truck. When the employees lower the
concrete chute, the supervisor should ensure that all employees are
wearing gloves and use the handles on the chute to lower it.
Before concrete pouring commences the concrete pouring the concrete
work safe work procedure (SWP 003) needs to be communicated to all
employees and signed. The concrete truck operator will only start
pouring once the supervisor has given the instruction.
Employees that are working on vibrating the concrete must wear gum
boots to prevent concrete getting into their shoes and on their skin. Full
PPE must be worn.
While employees are standing on the reinforced steel vibrating the
concrete, scaffold planks should be placed for them to walk on. No
employees are allowed to walk on reinforced steel.
Concrete being poured where employees have to work at height,
scaffolding will be provided for employees to stand on. Employees
working at heights will have the required training.
Scaffolds will be erected and inspected by competent appointed
employees. Employees working at heights will make use of a double
lanyard safety harness, and be hooked at all times. All scaffolding is
required to have toe boards, knee rails, handrails and access by ladder.
Any concrete spills must be cleaned up immediately and disposed of
properly. Concrete trucks may only clean their trucks at areas designated
by the client. This area needs to be cleaned regularly. In all cases a spill
kit will be on hand.
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All personnel to wear PPE at all times.

Shuttering and stripping will be done by competent shutter hands.
Working platforms will be kept clean.
MSDS for all products used in repair process will be obtained and
communicated to personnel.
During stripping nails on wood shutters to be removed and discarded.
Workers to be careful of pinch/nip points.
All operators of electrical equipment will be trained.
Sprinkling of water will be used to suppress dust during breaking and
drilling.
13.4 Using of a ladder
Training will be provided.

Daily toolbox talks will remind employees on how to use a ladder.
Not more than one person on a ladder.
When a person is on the ladder one person must always hold or support
the ladder.
Ladder instructions must be read and practiced daily.
Dont use the top 3 rungs on the ladders.
When you have tools that you want to use on the top of the ladder use a
bucket.
Three point contacts are very important.
Eyes on path at all times.
13.5 Personal Protective Equipment

We shall wear the Personal protective equipment clothing listed at all
times when on site. No workers shall be permitted on site without the
full PPE as specified.
Hard hat.
Goggles.
Overalls with high visibility reflector vest.
Steel toe boots / gumboots in wet areas.
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Dust mask.
Ear plugs (when working in a noisy area).
All employees will be equipped with their PPE and no one shall be
on site without the above required PPE.
The PPE clothing is applicable to everyone coming on site.
13.6 First Aid, emergency equipment and procedure
We will ensure that persons at work receive prompt first aid treatment
in case of injuries or emergency.
We will provide first aid box or boxes at or near the work place which
shall be available and accessible.
No persons are allowed to carry on with their task in case an emergency
siren or alarm sound.
Report any incident/accident immediately to supervisor or safety
representative on site.
Every minor injury shall be treated on site by the competent first aider
as OHS act.
All people working on site will undergo induction, safety awareness
training and environmental training with regarding emergency
procedures, fire, or electrical shut down.
13.7 Housekeeping (on daily basis)
We shall continuously maintain and implement housekeeping on our
construction site to avoid injuries to persons on site, client, visitors
and or sub-contractors.
Everything in its place. No materials or hand tools will be lying on the
ground when not in use.
We shall store them safely in the toolbox on site.
All waste scrap produced on site shall be removed at appropriate
intervals to enhance a healthy and safe environment for persons
working on site.
No smoking or dumping on site shall be permitted unless it is a
demarcated smoking area to avoid cigarette butts on the ground.
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14. ENVIROMENTAL
14.1 Vegetation Clearing and Topsoil Removal
SA Fence and Gate shall ensure that the clearance of vegetation is strictly
restricted to the area required for the work (such as the fence will be
erected, toilets will be placed and access roads where vehicles and workers
will walk).
All cleared vegetation will either be mulched and mixed into the topsoil
or disposed at an approved disposal site.
All disposal of vegetation by burying or burning is prohibited.
Topsoil will be stripped which will include the top 150mm of the soil, for
subsequent use during rehabilitation and re-vegetation.
14.2 Noise
The contractor does envisaged that the project will generate excessive
noise (more than 85 dB), but instances whereby the equipment such drilling
machine will be used, the workers will be advised to wear ear plugs.
14.3 Dust
It will be suppressed according to the clients standard environmental
specification. Eskoms Environmental officer will issue a permit to SA Fence
and Gate for extraction of water to be used for dust suppression. A water
tanker shall be permanently available on site for the control of dust
generation, and SA Fence and Gate shall ensure that the sprays do not
generate excess run off. During high wind conditions, SA Fence and Gate
shall comply with the Engineers instructions regarding dust dumping
measures.
An appropriate number of water tankers shall be permanently available for
the control of dust generation, and the Contractor shall ensure that the
sprays do not generate excess run off. There shall be sufficient water
tankers of adequate capacity to enable the dampening of all working areas
and access/ haul roads. During high wind conditions, the Contractor shall
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comply with the Engineers instructions regarding additional dust-damping

measures.
14.4 Emergency preparedness
Telephone numbers of emergency services, including local fire fighting
services are pasted in all offices of SA Fence and Gate, and all employees
are made aware on the evacuation routes, from all their workplace, in case
there is an emergency of fire for them to relocate their workplace.
Assemble points are noted for such cases.
14.5 Accidental leaks and spillages
In the event of a spill, the source of the spillage shall be isolated, the
spillage will be contained. The area where the pillage incident has occurred
shall be cordoned off and secured. SA Fence and Gate shall maintain spill
kits on the site at all times and shall ensure that there is always adequate
supply of absorbent material available in the spill kit.
14.6 Flora and Fauna
Poaching of animals will not be allowed on site, should animals be seen on
site, the will be reported to the Environmental Officer competent to rescue
such animals.
14.7 Ablution facilities
SA Fence and Gate shall provide adequate ablution facilities for workers in
the construction camp. Acts of excretion and urination shall be strictly
prohibited other than at the facilities provided.
I.
Toilets shall be located within 100 m from any points of work

but not closer than 50 meters to any watercourse or water
body,
II.
Mobile toilets will be provided so that it will be moved as the

process of fence erection goes on.
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III.
Toilets shall be secured to the ground to prevent them from

toppling due to wind or any other cause;
IV.
No spillage shall occur when the toilets are cleaned or emptied

and the contents shall be properly removed from site by
Sanitech,
V.
Discharge of waste from toilets into the environment and burial

of waste is strictly prohibited,
VI.
Toilets shall be provided with external closing mechanism to

prevent toilet paper from being blown out, and
VII.
Toilets will be emptied before long weekends and builders

holidays and shall be locked after working hours.
14.8 Solid waste management

The management of solid waste at the working area shall be strictly
controlled and monitored; the quantities of waste generated shall be
minimized as wheelie bins will be provided by Roshcon. Littering will be
avoided, there will be no burying, dumping and burning of waste material
shall occur. Bins shall never be allowed to overflow and shall be emptied
twice in a week. All solid waste will be collected by Roshcon and be
disposed off-site at an approved landfill site.
14.9 Accommodation of traffic
SA Fence and Gate shall ensure vehicle traffic safety at all times and shall
implement safety measures. Fence and Gate shall control the movement of
all the vehicles and equipment including of the suppliers so that they
remain on designated routes. On gravel road on the site and within 500 m
of the site, the vehicles of Fence and Gate and the suppliers shall not
exceed a speed of 40 km/h.
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14.10 Landscaping and Rehabilitation

Rehabilitation will be done during the process of erecting (on-going process
e.g. before erecting fence on point B, the top soil that was removed from
point A, will be backfilled to where it was removed).
14.11 Prevention of fire
SA Fence and Gate shall take adequate precautions to ensure that the fire
hazard on and near the site is reduced to a minimum. Smoking shall not be
permitted on site, it will only be allowed in areas designated as smoking
area.
14.12 Installation
Installation of all material will be done as per the clients standard
environmental specification, together with the addendum from DEA.
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Method Statement For Fence Bridges and Drop Structures

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SA FENCE AND GATE

Investment Holdings (Pty) Ltd

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

Delivery and offloading

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

QA/QC MEANS QUALITY ASSURANCE /QUALITY CONTROL OFFICER

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

5. RESPONSIBILITIES, AUTHORITY, ACCOUNTABILITY

6. STRIPPING AND STOCKPILE AREA

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

7. PLANT & TOOLS REQUIRED FOR THE ACTIVITY

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

Spirit Level and builders line

Backfilling: The act of reintroducing excavated material to a specific

SANS: South African National Standards.

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

layout of the excavation area will be marked out by using either

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

All excavations are to be shored unless the excavation is sloped. Steep

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

8.4.2 Main fill

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

9.3.4 Fixing of Reinforcing Steel

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

Concrete will be levelled with shovels and straight edge.

9.6.5 Centre Wall (Bridges)

Shuttering wall will be put in place, placed in line and stayed.

9.6.6 Top slab (Bridges)

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

Erection of the formwork will take place in accordance with the

Rapid Hardening OPC

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

Care will be taken to remove material carefully to prevent shock or damage

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

SA FENCE AND GATE

Doc No. SAFG Eskom Kusile

Shading the aggregates before placing